Training module

on

7 QC Tools
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 7 QC TOOLS
• Pareto Diagram
• Stratification
•Scatter Diagram
•Cause and Effect Diagram
•Histogram
•Check Sheet
•Control Chart/Graph

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What are 7 QC Tools ?
QC tools are the means for Colleting data ,
analyzing data , identifying root causes and
measuring the results.
THESE TOOLS ARE RELATED TO
Numerical DATA processing

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Application of QC tools in Problem Solving
Identification of problem

Defining the problem

Record of facts

Detecting causes of problem

Evaluation of result

Process control ( Standardization )

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Pareto Diagram
1. What is Pareto diagram ?
A Pareto diagram is a combination of bar and line graphs of
accumulated data, where data associated with a problem
(e.g., a defect found, mechanical failure, or a complaint
from a customer) are divided into smaller groups by cause
or by phenomenon and sorted, for example, by the number
of occurrences or the amount of money involved.

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Pareto Diagram
2. When is it used and what results will be obtained?

It is mainly used to prioritize matters, and

because of its easiness of use, the diagram is
used in a wide variety of fields.

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Pareto Diagram
Method Usage
Used to identify a problem.
Pareto Diagram Used to identify the cause of
(No. of Occurrences) a problem.
Used to review the effects of
an action to be taken.
Used to prioritize
actions.(Used during
phases to monitor the
situation, analyze causes,
and review effectiveness of
an action.)
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Result
Allows clarification of
important tasks.
Allows identification
of a starting point
(which task to start
with).
Allows projection of
the effects of a measure
to be taken
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Pareto Diagram
Example

Assessment using Pareto Confirmation of Effect

diagram (prioritization) (Comparison)
To identify a course of
action to be emphasized Frequently used to check
using a variety of data. the effect of an
improvement.
Details of “ A”

Improved

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Stratification
1. What is Stratification ?

Stratification means to “divide the whole into smaller portions

according to certain criteria.” In case of quality control,
stratification generally means to divide data into several groups
according to common factors or tendencies (e.g., type of defect
and cause of defect).
Dividing into groups “fosters understanding of a situation.”
This represents the basic principle of quality control.

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Stratification
2. When is it used and what results will be obtained?
The “common and basic principle” of quality control is
stratification, i.e., to think a matter out by breaking it
into smaller portions. Stratification has a number of
useful purposes.

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Stratification
Item Method of Stratification
Hour, a.m., p.m., immediately after start of work,
Elapse of time
shift, daytime, nighttime, day, week, month
Worker, age, male, female, years of experience,
Variations among workers
shift, team, newly employed, experienced worker
Processing method, work method, working
Variations among work
conditions (temperature, pressure, and speed),
methods
temperature
Variations among Measurement tool, person performing
measurement/inspection measurement, method of measurement, inspector,
methods sampling, place of inspection

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Scatter Diagram
1. What is Scatter Diagram ?

A scatter diagram is used to “examine the relationship between

the two, paired, interrelated data types, ” such as “height and
weight of a person.” A scatter diagram provides a means to
find whether or not these two data types are interrelated. It is
also utilized to determine how closely they are related to
identify a problem point that should be controlled or improved.

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Scatter Diagram

ｙ Axis
Abrasion (micron)

x Axis
Number of
Rotations

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Cause & Effect Diagram
1. What is Cause & effect Diagram ?
A cause and effect diagram is “a fish-bone diagram that
presents a systematic representation of the relationship
between the effect (result) and affecting factors (causes).”
Solving a problem in a scientific manner requires
clarification of a cause and effect relationship, where the
effect (e.g., the result of work) varies according to factors
(e.g., facilities and machines used, method of work, workers,
and materials and parts used). To obtain a good work result,
we must identify the effects of various factors and develop
measures to improve the result accordingly.

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Cause & Effect Diagram
2. When is it used and what results will be obtained?

A cause and effect diagram is mainly used to study

the cause of a certain matter. As mentioned above,
the use of a cause and effect diagram allows
clarification of causal relation for efficient problem
solving. It is also effective in assessing measures
developed and can be applied to other fields
according to your needs.

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Cause & Effect Diagram
Method Usage Result
Used when Can obtain a clear
overall picture of causal
Cause and Effect clarifying a cause relation. (A change in
Diagram
Machine Man
and effect the cause triggers a
relationship.[Used variation in the
Effect

during a phase to result.)○ Can clarify

analyze causes.] the cause and effect
Material Method
relationship.
Cause (4M’s) Result
(Controlled State)  Used to develop
countermeasures. Can list up all causes
to identify important
causes.
[Used during a phase to plan
countermeasures.] Can determine the
direction of action
(countermeasure).

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Cause & Effect Diagram
Mechanism of Quality of
Copying Machine Copying Paper

Many Copying Errors!

Malfunction of
Running out
Smudges on the the roller
of stock
copied surface
Printing too Too thin
Internal devices not lightly
working smoothly Dampened
Folded

Deterioration of
Error in
performance due
Keyboard handling placement of Dirt on the
to high
error paper (setting glass
temperatures
its face up) surface
Error in selecting a
Dust
scale of reduction Error in Nicotine-
selecting stained
shading
User Surrounding
Environment

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Check Sheet
1. What is Check sheet ?
A check sheet is “a sheet designed in advance to allow easy
collection and aggregation of data.” By just entering check
marks on a check sheet, data can be collected to extract
necessary information, or a thorough inspection can be
performed in an efficient manner, eliminating a possibility
of skipping any of the required inspection items.
A check sheet is also effective in performing stratification
(categorization).

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Check Sheet
2. When is it used and what results will be obtained?

It is frequently used in daily business operations,

often not specifically only for QC purposes.

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Check Sheet
Method Usage Result
Ensures collection of
Check Sheet Used to collect required data.
Day
Process
data. Allows a thorough
Process 1

Used when inspection of all check

Process 2
items.
Process 3
performing a
thorough inspection. Can understand
Used during phases to monitor tendencies and
the situation, analyze causes, variations.
review effectiveness of an Can record required
action, perform data.
standardization, and
implement a selected control
measure

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Check Sheet
A check sheet used to identify defects

Date
Total
Defect
Vertical Scratch

Scratch

Dent

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Histogram
1. What is Histogram ?

When creating a histogram, “a range of data is divided into

smaller sections having a uniform span,and the number of data
contained in each section (the number of occurrences) is
counted to develop a frequency distribution table.” Then, “a
graph is formed from this table by using vertical bars, each
having the height proportional to the number of occurrences in
each section.”

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Histogram
2. When is it used and what results will be obtained?
A histogram is mainly used to analyze a process by
examining the location of the mean value in the
graph or degree of variations, to find a problem point
that needs to be improved.

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Histogram

Frequency Distribution Table Standard Standard

Cutting Length of Steel Wire] Lower Limit Upper Limit

(Standard: 255±5 mm)

Product
Section Mean Frequency Marking Occurrences Standard Value

[Histogram of Cutting Length of Steel

Wire]

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Control Chart (Control Chart / Graph 1)
1. What is Control Chart ?
A control chart is used to examine a process to see if
it is stable or to maintain the stability of a process.
This method is often used to analyze a process. To
do so, a chart is created from data collected for a
certain period of time, and dots plotted on the chart
are examined to see how they are distributed or if they
are within the established control limit. After some
actions are taken to control and standardize various
factors, this method is also used to examine if a
process is stabilized by these actions, and if so, to
keep the process in a stable state.
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Control Chart
2. When is it used and what results will be obtained?
A control chart is used to identify dots that are outside
the control limit, which indicate some anomalies in a
process. In addition, seven consecutive dots showing
values that are below or above the mean (central)
value, or an increment or a decline represented by
seven consecutive dots also indicate “a problem in a
process.”
We need to examine what has caused such a
tendency or an increment/decline.

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Control Chart
Method Usage Result
Used to observe a Can identify a change
Control Chart
caused by elapse of
change caused by
time.
elapse of time.
Can judge the
[Used during phases to
process if it is in its
monitor the situation,
normal state or there
x-R Control Chart analyze causes, review
are some anomalies
effectiveness of an
by examining the dots
action, perform
plotted on the chart.
standardization, and
implement a selected In the example “x bar ” -R
control chart, “X bar”
control measure represents the central value,
while “R” indicates the range.
Control Chart for Managerial Purposes: Extends the line indicating the control limit used for analytical purposes to
plot data obtained daily to keep a process in a good state.
Control Chart for Analytical Purposes: Examines a process if it is in a controlled state by collecting data for a certain
period of time. If the process is not controlled, a survey is performed to identify its cause and develop
countermeasures.

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Control Chart
Examples of Values
Represented by Dots

Values above the

control limit
represented by
seven
consecutive dots

x- Control Chart
A decline
represented by
seven
consecutive dots

Group Number

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To sum up 7 QC tools (Numerical data ) are used as follow:

• Pareto Diagram To identify the current status and issues

• Stratification Basic processing performed when
collecting data
• Scatter Diagram To identify the relationship between two
things
• Cause and Effect Diagram
To identify the cause and effect relationship
• Histogram To see the distribution of data

• Check Sheet To record data collection

• Control Chart/Graph To find out abnormalities and identify the
current status

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Thank you

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